Mercedes-Benz Sprinter / Dodge Sprinter. Manual — part 409

Fig.

7

FRAME

DIMENSIONS

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FRAME & BUMPERS

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SPECIFICATIONS - TORQUE

TORQUE SPECIFICATIONS

DESCRIPTION

N·m

Ft. Lbs.

In. Lbs.

Brake line nuts

14

10

—

Brake pads wear

indicator caliper

bolt

10

7

89

Engine cradle bolts

125

92

—

Engine mount bolt

to engine bracket

83

61

—

Engine mount nuts

to engine cradle

45

33

—

Power steering line

nuts

37

27

—

Steering gear

mounting bolts -

1st stage

25

18

—

Steering Gear

mounting bolts -

2nd stage

45

33

—

Steering Gear

mounting bolts -

3rd stage

90°

—

—

Steering gear u-

joint bolt

24

18

—

Sway bar bushing

bolts

30

22

—

Trailer hitch angle

bracket bolts/nuts

50*

See

Warning

37*

See

Warning

—

Trailer hitch frame

bolts

110

81

—

Transmission cross-

member nuts

45

33

—

Transmission

mount bolts/nuts

45

33

—

WARNING: Microencapsulated bolts and self-lock-
ing nuts may only be used once. If you use
microencapsulated bolt or self-locking nuts more
than once, the self-locking function is rendered
useless. The trailer hitch may become detached
from the vehicle, possibly resulting in a serious risk
of injury and/or damage to property, including dam-
age to the vehicle.

ENGINE CRADLE CROSSMEM-
BER

REMOVAL

(1) Install engine support tool 8534 or equivalent.
(2) Raise

and

support

the

vehicle.

(Refer

to

LUBRICATION

&

MAINTENANCE/HOISTING

-

STANDARD PROCEDURE)

(3) Remove engine mount nuts. (Fig. 8)

(4) Remove front spring. (Refer to 2 - SUSPEN-

SION/FRONT/SPRING - REMOVAL)

(5) Remove calipers. (Refer to 5 - BRAKES/HY-

DRAULIC/MECHANICAL/DISC BRAKE CALIPERS
- REMOVAL) (Fig. 9)

Fig. 8 ENGINE MOUNT

1 - ENGINE MOUNT
2 - SHIELD
3 - NUTS (2 PER MOUNT)

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FRAME & BUMPERS

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(6) Cut tie straps holding wheel speed sensor and

brake pad wear sensor wire harness to the cradle.

(7) Cut tie straps holding transmission harness to

the cradle.

(8) Remove lower pinch bolt from steering shaft

and disconnect shaft. (Fig. 10)

(9) Siphon the power steering fluid out of the res-

ervoir.

(10) Remove both the high pressure and return

hoses from the steering gear (Refer to 19 - STEER-
ING/PUMP/HOSES - REMOVAL) (Fig. 10).

(11) Remove bolt and remove power steering hose

support bracket from the cradle. (Fig. 11)

(12) Disconnect brake lines from body side, at the

couplings. (Fig. 12)

(13) Support engine cradle with suitable lifting

device.

(14) Remove four cradle support bolts from each

side of the cradle. (Fig. 13)

Fig. 9 FRONT DISC BRAKE CALIPER

1 - WEAR INDICATOR CABLE
2 - WEAR INDICATOR
3 - BOLT
4 - BRAKE HOSE
5 - DISC BRAKE CALIPER/ADAPTER
6 - ADAPTER BOLTS

Fig. 10 STEERING GEAR

1 - U-JOINT
2 - HIGH PRESSURE POWER STEERING HOSE
3 - RETURN HOSE
4 - OUTER TIE ROD END RETAINING NUT
5 - STEERING GEAR
6 - STEERING GEAR RETAINING BOLT
7 - STEERING GEAR NUT
8 - WASHER
9 - ENGINE MOUNT BOLT
10 - U-JOINT CLAMPING BOLT

Fig. 11 POWER STEERING HOSE BRACKET

1 - POWER STEERING LINE
2 - SUPPORT BRACKET BOLT

Fig. 12 BRAKE LINES

1 - BRAKE LINES
2 - LINE COUPLINGS

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FRAME & BUMPERS

13 - 9

(15) Lower engine cradle.
(16) Release support clips and remove brake lines.
(17) Remove nuts and remove jounce bumpers.
(18) Remove nuts and remove mount heat shield.

(Fig. 14)

(19) Remove stabilizer bar as necessary. (Refer to 2

-

SUSPENSION/FRONT/STABILIZER

BAR

-

REMOVAL)

(20) Remove steering gear. (Refer to 19 - STEER-

ING/GEAR - REMOVAL)

(21) Using a sharp flat bladed tool, remove identi-

fication plate. (Fig. 15)

INSTALLATION

(1) Using a suitable RTV sealant, attach identifica-

tion plate to engine cradle.

(2) Install steering gear onto engine cradle. (Refer

to 19 - STEERING/GEAR - INSTALLATION)

NOTE: Steering gear must be torqued in a three
step procedure below.

(3) Tighten steering gear bolts in three stages as

follows.

1. Tighten to 25 N·m (18 ft. lbs.)
2. Then tighten to 45 N·m (33 ft. lbs.)
3. Then tighten bolts an additional 90°.
(4) Install stabilizer bar. (Refer to 2 - SUSPEN-

SION/FRONT/STABILIZER BAR - INSTALLATION)

(5) Install heat shield and nuts.
(6) Install jounce bumpers and install nuts.
(7) Install support clips and brake lines.
(8) Raise engine cradle into place and install bolts.
(9) Tighten bolts to 125 N·m (92 ft. lbs.).
(10) Connect brake lines at couplings and tighten

to 14 N·m (10 ft. lbs.).

(11) Position power steering hose and install sup-

port bracket bolt.

(12) Install both power steering hoses at steering

gear. (Refer to 19 - STEERING/PUMP/HOSES -
INSTALLATION)

(13) Connect steering shaft to gear and install the

lower pinch bolt.

(14) Tighten lower pinch bolt to 24 N·m (18 ft.

lbs.).

(15) Install new tie straps holding transmission

harness to cradle.

(16) Install front spring. (Refer to 2 - SUSPEN-

SION/FRONT/SPRING - INSTALLATION)

(17) Install engine mount nuts and tighten to 45

N·m (33 ft. lbs.).

Fig. 13 ENGINE CRADLE BOLTS

1 - ENGINE CRADLE
2 - CRADLE BOLTS (4 PER SIDE)

Fig. 14 HEAT SHIELD

1 - HEAT SHIELD
2 - NUTS

Fig. 15 IDENTIFICATION PLATE

1 - IDENTIFICATION PLATE
2 - ENGINE CRADLE

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